Flexible package and process of making package

ABSTRACT

A flexible package and method for making one includes a thermoplastic film section folded to form first and second opposing body panels. The first and second body panels are joined together along a top seal, first side seal, and second side seal; and have a fold section forming a bottom. A perforated section is provided in the first body panel to provide access to an interior of the package. The package can be used for a variety of packaging contents including, for example, a roll of bags.

This application claims priority to U.S. provisional patent application 61/789,761, filed Mar. 15, 2013, incorporated herein by reference in its entirety.

TECHNICAL FIELD

This disclosure relates to flexible packages. More particularly, this disclosure relates to a flexible package having a perforated section for accessing a package interior, and methods of making such packages.

BACKGROUND

Some products need to be packaged for displaying and selling at the retail level. Some packages can be bulky and take up undesirable amounts of shelf space. Many packages have no use after being a package, and they result in waste after serving their packaging function. Some packages are not self-supporting, and do not allow the package to be displayed upright. Improvements in packaging are desirable.

SUMMARY

In the first aspect, a method of making a flexible package is provided. The method includes providing a thermoplastic film including a first film portion adjacent to a second film portion joined at a fold. The method includes forming a perforated section in the first film portion; forming a first side seal between the first film portion and second film portion; and inserting packaging contents between the first and second film portions. The method includes forming a top seal and second side seal between the first film portion and second film portion, with the packaging contents contained between the first side seal, second side seal, top seal, and fold. The first film portion contains the perforated section. The method includes cutting along at least the second side seal to result in an individual flexible package.

In some aspects, the method includes inserting a gussetter into the fold to form a gusset between the first film portion and the second film portion.

In another aspect, a flexible package is provided. The flexible package includes a thermoplastic film section folded to form first and second opposing body panels. The first and second body panels are joined together along a top seal, first side seal, and second side seal, and have a fold section forming a bottom. The first and second body panels define an interior volume therein. The package includes a perforated section in the first body panel. The package includes packaging contents in the interior volume.

In some aspects, the perforated section includes a perforated looped section sized to permit access to the packaging contents in the interior volume, when the perforated looped section is removed from the first body panel.

In some aspects, the fold section includes a gusset.

A variety of examples of desirable product features or methods are set forth in part in the description that follows, and in part will be apparent from the description, or may be learned by practicing various aspects of this disclosure. The aspects of the disclosure may relate to individual features as well as combinations of features. It is to be understood that both the foregoing general description and the following detailed description are explanatory only, and are not restrictive of the claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flowchart showing a method of making a flexible packaging, in accordance with principles of this disclosure;

FIG. 2 is a schematic diagram of one step in the method of FIG. 1;

FIG. 3 is a schematic diagram of the step shown in FIG. 2;

FIG. 4 is a schematic diagram illustrating results of the step of FIGS. 2 and 3;

FIG. 5 is a schematic diagram of further steps in the method of FIG. 1;

FIG. 6 is a front view of a flexible package made according to the method of FIG. 1;

FIG. 7 is a rear view of the flexible package of FIG. 6; and

FIG. 8 is a bottom view of the flexible package of FIGS. 6 and 7.

DETAILED DESCRIPTION

A method of making a flexible package, such as flexible package 12 shown in FIGS. 6-8, is shown in FIG. 1 in general at 10.

The flexible package 12 will typically be made from a flexible material, such as a polymeric film. The polymeric film can be, for example, a thermoplastic film. In some examples, the thermoplastic film will be a film of polyethylene. One useful film is polyethylene having a thickness of about 2.5 mil.

At a first step 14, the film 16 (FIGS. 2, 3, and 5) is provided. The film 16 will typically be provided by unwinding the film 16 from a roll of the film 16. In some implementations, the film 16 may be pre-folded film, which includes a first film portion 17 (FIGS. 2 and 3) adjacent to a second film portion 19 (FIG. 5) joined at a fold 15 (FIG. 5). In FIG. 5, which detail is later provided, it should be understood that the folded film 16 is being shown schematically, and a top film portion visible in FIG. 5 is the second film portion 19. The first film portion 17, in FIG. 5, is underneath the second film portion 19, with the first and second film portions 17, 19 being joined at the fold 15.

In some methods, the step 14 of providing film 16 includes unwinding the film 16 from a roll, and then after unwinding, folding the film 16 into “C-folded film” 21 (FIG. 5). By the term “C-folded film” 21, it is meant that the film 16 is folded once onto itself to result in having the first film portion 17 adjacent (or against) the second film portion 19 and joined at the fold 15.

After providing the film 16, there is a step 18 of forming a perforated section 20 (FIGS. 2 and 6) in the first film portion 17. The perforated section 20 can be formed in many different ways. In the example shown in the drawings, the perforated section 20 is formed by forming perforations 22 (FIGS. 2 and 4) in the first film portion 17. One schematic example is shown in FIG. 2.

In FIG. 2, it can be seen how as the first film portion 17 is transported in direction of arrow 24, a blade 26 will cut perforation slits 28 (FIGS. 3 and 4) into the first film portion 17. The blade 26 will move in a direction 30 to cut the slits 28 and form perforated section 20. The film 16 can include an eye mark 32, such that a visual manufacturing eye can detect the location on the film 16 of where to place the perforations 22, as the film 16 moves along the processing line. The perforator wheel 34 can be aligned with an edge 35 of the film 16 to help properly locate it. Many variations are possible.

FIG. 3 is another schematic diagram showing further non-limiting example details of possible ways to carry out step 18 in forming perforated section 20. The blade 26 is shown to be part of perforator wheel 34, which rotates in a direction 38 about an axis that can be about parallel to the plane of the film 16. Many different embodiments are possible. Perforation strength can be adjusted by increasing or decreasing a depth (A) of engagement, which increases or decreases the length (B) of each slit 28 and the amount of uncut film (C) in between the blades 26. The depth (A) of engagement can be controlled by a threaded rod, in some non-limiting examples.

FIG. 4 illustrates one example pattern 36 of perforations 22 generated by the perforator wheel 34 of FIG. 3. The slits 28 have length (B) and are separated from the next adjacent slit 28 by a region of uncut film (C). Many variations are possible.

The perforated section 20 can be of a size and shape that allows access to, or dispensing of, contents of the flexible package 12. This size and shape can vary, depending upon the particular application. In the example shown in FIG. 2, the perforated section 22 forms a looped section 40. In the non-limiting example shown in FIG. 2, the looped section 40 forms an oval or elliptical shape. Of course, there can be many different shapes.

In the step 18 of forming perforated section 20 in the first film portion 17, in this embodiment, the perforated section 20 is formed in only the first film portion 17 in the C-folded film 21. Thus, in some example embodiments, before the step 18 of forming the perforated section 20, there is a step of separating the first film portion 17 from the second film portion 19. This step can be done, for example, by using a separator to split the C-folded film 21, which can be done by moving the first film portion 17 and second film portion 19 away from each other, such that they are not pressing against each other. This physical separation will allow the perforator wheel 34 to form the perforations 22 in the first film portion 17 without cutting the second film portion 19.

The method 10 may include a step 42 of adding a gusset 44 (FIG. 8). This step 42 can be accomplished by inserting a gussetter into the fold 15 between the first film portion 17 and second film portion 19 to form the gusset 44 between the first film portion 17 and second film portion. The gussetter can be in a form of a gusset plate, inserted into the fold 15 of the C-folded film 21. The depth of the gusset 44 can be adjusted, depending upon how far one inserts the gusset plate into the fold 15. In some embodiments, if a wide bottom or base is not desired for the resulting flexible package 12, this step 42 can be omitted. Many variations are possible.

Still in reference to FIG. 1, the method 10 may include a step 46 of making a first side seal 48. In FIG. 5, the first side seal 48 is typically made transverse to the film direction shown at arrow 50. The first side seal 48 can be made through a variety of techniques, including engaging a seal bar 60 against the film 16 to form a heat seal between the first film portion 17 and second film portion 19. As will be explained in more detail below, in some example processes, the step 46 of making the first side seal 48 for one package will occur at the same time that a second side seal 64 is made for another package downstream of it. This example process is explained below.

In FIG. 5, reference numeral 62 is pointing in phantom to a downstream incomplete package 62 in the making, while reference numeral 66 is pointing in phantom to an upstream incomplete package 66 in the making. In FIG. 5, upstream incomplete package 66 immediately follows downstream incomplete package 62 in the process.

In the example embodiment shown, the first side seal 48 is formed by seal bar 60. While there can be many variations, in the variation shown in FIG. 5, the seal bar 60 will form the first side seal 48 for upstream incomplete package 66 at the same time it forms second side seal 64 for the downstream incomplete package 62. In FIG. 5, the first side seal 48 for upstream incomplete package 66 is shown in broken lines under the seal bar 60. The second side seal 64 for downstream incomplete package 62 is shown in broken lines under the seal bar 60.

In method 10, after the first side seal 48 is formed, there is a step 52 of inserting packaging contents 54. This step 52 will include inserting packaging contents 54 between the first film portion 17 and second film portion 19. In FIG. 5, the packaging contents 54 are shown being moved in the direction of arrow 56 into a pocket 58. The pocket 58 is formed by the first film portion 17 and second film portion 19 being joined together by the fold 15 and first side seal 48.

The packaging contents 54 can be any of a variety of contents. In one non-limiting example, the packaging contents 54 include a roll of bags 68.

The method 10 can include the step 74 of forming a top seal 70 and forming the second side seal 64 between the first film portion 17 and second film portion 19, with the packaging contents 54 contained between the first side seal 48, second side seal 64, top seal 70, and fold 15. The first film portion 17 will include the perforated section 20 therein. In one example of step 74, as mentioned previously, the second side seal 64 can be formed with the seal bar 60. In some embodiments, the seal bar 60 can be in the form of an L-shaped seal bar 72. In FIG. 5, the L-shaped seal bar 72 is shown forming the top seal 70, which is depicted in broken lines underneath the L-shaped seal bar 72. When the L-shaped seal bar 72 is used, the top seal 70 and second side seal 64 are formed simultaneously. In addition, the L-shaped seal bar 72 forms the first side seal 48 for the next package in the processing line, depicted in this embodiment as upstream incomplete package 66. Many variations are possible.

The method 10 can include cutting along at least the second side seal 64 to result in the individual flexible package 12. In example implementations, the step of cutting along the second side seal 64 will occur simultaneously with the step 74 of forming the second side seal 64. As explained previously, this can also occur at the same time as the first side seal 48 is formed for the next package in the line, shown as the upstream incomplete package 66.

When the L-shaped sealing bar 72 is used, the step of cutting along at least the second side seal 64 can also include cutting along the top seal 70. In some example processes, at the same time as forming top seal 70 and second side seal 64, the L-shaped seal bar 72 will cut along both the top seal 70 and the second side seal 64.

In some example processes, when the cutting occurs along the top seal 70, scrap results at 78 (see FIG. 5). The method 10 can include a step 76 of collecting the scrap 78. The collected scrap 78 may be wound onto a roller. The scrap 78 can then be used for other purposes.

In FIG. 5, the resulting flexible package 12 is shown schematically. The flexible package 12 includes first side seal 48, opposite second side seal 64, top seal 70, and bottom fold 15. The packaging contents 54 are within the interior of the package 12. The bottom fold 15 may optionally include gusset 44 (FIG. 8).

The method 10 can include at step 80, putting the individual flexible packages 12 onto a conveyer. In some methods, after the step 74 of forming the seals and cuts is completed, the formed flexible package 12 can fall by gravity onto a conveyer, where it is then moved downstream.

FIGS. 6-8 show the flexible package 12 that is made according to the method 10 of FIG. 1. In reference to FIGS. 6-8, the package 12 includes film 16 folded to form first and second body panels 82, 84 opposing each other. The first and second body panels 82, 84 are the result of the first film portion 17 and second film portion 19 in the method 10 explained above. The first and second body panels 82, 84 are joined together along the top seal 70, first side seal 48, and second side seal 64. The fold section 15 forms a bottom 86. The fold section 15 can also include gusset 44, forming the bottom 86. The first and second body panels 82, 84 define an interior volume 88 (shown in phantom in FIGS. 6 and 7) therein.

The first body panel 82, which is made from the first film portion 17 having perforated section 20, includes a perforated section 90 in the first body panel 82. The perforated section 90, in the non-limiting example shown, results from the perforated looped section 40 (FIG. 2) formed in first film portion 17. The perforated section 90 is sized to permit access to the interior volume 88 to either access or dispense the packaging contents 54, after the perforated section 90 is removed from the first body panel 82.

As mentioned above, the packaging contents 54 can include the roll of bags 68. In such an example, the user will access the interior volume 88 by removing the perforated section 90 to result in a hole in the first body panel 82. The user will then grasp the roll of bags 68 through the hole in the first body panel 82. The bags in the roll of bags 68 can then be dispensed, individually if desired, through the hole resulting from the removed perforated section 90.

In FIGS. 6 and 7, it can be seen how the package 12 is self-supporting in an upright position when oriented on the package bottom 86. This can help with displaying the product on the shelf of a retailer.

The resulting flexible package 12 will utilize less space than current packaging in the form of a cardboard carton. This allows for more product in the same space on the shelf of the retailer. The flexible package 12 uses less material to package the roll of bags 68, than when a carton is used. Typically, there is about an 80% reduction in packaging material weight of flexible package 12, as compared to a cardboard carton. The flexible package 12, made with the polymeric film 16 will protect the packaging contents 54 from fluids, which might otherwise migrate through a cardboard carton. The packaging contents 54, such as a roll of bags 68, will be convenient to dispense through the opening created by the removed perforated section 90.

The above description represents example principles of this disclosure. Many embodiments can be made applying these principles. 

What is claimed is:
 1. A method of making a flexible package; the method comprising: (a) providing a thermoplastic film including a first film portion adjacent to a second film portion joined at a fold; (b) forming a perforated section in the first film portion; (c) forming a first side seal between the first film portion and second film portion; (d) inserting packaging contents between the first and second film portions; (e) forming a top seal and second side seal between the first film portion and second film portion, with the packaging contents contained between the first side seal, second side seal, top seal, and fold; the first film portion containing the perforated section; and (f) cutting along at least the second side seal to result in an individual flexible package.
 2. A method according to claim 1 further comprising: (a) inserting a gussetter into the fold to form a gusset between the first film portion and second film portion.
 3. A method according to claim 1 wherein: (a) the step of forming a perforated section includes perforating a looped section in the first film portion.
 4. A method according to claim 1 wherein: (a) the step of cutting along at least the second side seal further includes cutting along the top seal.
 5. A method according to claim 1 wherein: (a) the steps of (i) forming a top seal and second side seal, and (ii) cutting along at least the second side seal, occur simultaneously.
 6. A method according to claim 1 wherein: (a) the step of providing a thermoplastic film includes unwinding pre-folded film from a roll, the pre-folded film including the first film portion adjacent to the second film portion joined at the fold.
 7. A method according claim 1 wherein: (a) the step of providing a thermoplastic film includes unwinding film from a roll and then folding the film into the first film portion adjacent to the second film portion joined at the fold.
 8. A method according to claim 1 wherein: (a) before the step of forming a perforated section in the first film portion, separating the first film portion from the second film portion.
 9. A method according to claim 1 wherein: (a) the step of forming a top seal and second side seal between the first film portion and second film portion occurs simultaneously.
 10. A method according to claim 1 wherein: (a) the step of forming a top seal and second side seal between the first film portion and second film portion is done with a single seal bar having an L-shape.
 11. A method according to claim 1 further including: (a) after the step of cutting along at least the second side seal to result in an individual flexible package, putting the individual flexible package on a conveyor.
 12. A method according to claim 1 wherein: (a) the step of inserting packaging contents between the first and second film portions includes inserting a roll of bags between the first and second film portions.
 13. A flexible package made according to claim
 1. 14. A flexible package comprising: (a) a thermoplastic film section folded to form first and second opposing body panels; the first and second body panels being joined together along a top seal, first side seal, and second side seal; and having a fold section forming a bottom; the first and second body panels defining an interior volume therein; (b) a perforated section in the first body panel; and (c) packaging contents in the interior volume.
 15. A flexible package according to claim 14 wherein: (a) the perforated section includes a perforated looped section sized to permit access to the packaging contents in the interior volume, when the perforated looped section is removed from the first body panel.
 16. A flexible package according to claim 14 wherein: (a) the fold section includes a gusset.
 17. A flexible package according to claim 14 wherein: (a) the packaging contents include a roll of bags.
 18. A flexible package according to claim 14 wherein: (a) the package is self-supporting in an upright position when oriented on the bottom. 